Note: Descriptions are shown in the official language in which they were submitted.
D-85-1-005 - 1 - PATE~T
REPLACEABLE AUTOMOBILE HEADLIGHT LAMP UNIT AND
AUTOMOBILE HEADLIGHT ~TILIZING SAME
CROSS REFERENCE TO COPENDING APPLICATIONS
In U.S. Patent No. 4,528,619, filed June 24, 1983 and
entitled "Replaceable Lamp Unit Providing Hermetic Seal And
Fixed Alignment For Electric Lamp Contained Therein And
Automobile Headlight Utilizing Same" (inventors: R. J. Dolan et
10 al), there i~ described an automobile headlight and replaceable
lamp unit for use therein wherein the unit's insulative holder
includes conical-shaped apertures having similarly shaped
eyelets secured therein and at least two conductive lug members
mechanically connected (e.g., by crimping) to the eyelets to
15 seal the eyelets and provide positive electrical connection
thereto.
In U.S. Patent No. 4,623,958, filed January 15, 1985 and
entitled "Replaceable Automobile Headlight Lamp Unit"
~inventors: J. R. Van der Linde et al), there is described a
20 replaceable lamp unit wherein the unit's lamp has a clamp
secured thereto which includes a plurality of flange segments
thereon. These segments align with and are secured to a
s]otted insert which is securedly retained within the unit's
insulative holder.
In U.S. Patent No. ~,569,005, filed January 15, 1985 and
entitled "Replaceable I,amp Unit and Automobile Headlight
Utilizing Same" (inventors: J. ~. Bergin et al), there is
described a replaceable lamp unit having a clamp secured to the
lamp's base and including curved flange portions which can be
; 30 rotatably aligned on similarly curved outer surfaces of an
insert member and welded thereto. The insert is securedly
retained within the unit's holder.
c,~
~s~
D-85-1-005 - 2 - PATENT
In U.S. Patent No. ~,569,006, filed January 15, 1985 and
enti.tled "Replaceable Lamp Unit And Automobile Headlight
Utilizing ~ame" (inventors: B. Warren et al), there is
described a replaceable lamp unit wherein a clamp, secured to
5 the lamp's sealed end, is frictionally inserted within the
unit's insert member and thereafter secured (e.g., welded)
-thereto. The insert member is only partly inserted within the
unit's holder -to enable the aforementioned securement to be
accomplished externally of the holder.
In addition to the above, in U.S. Patent No. 4,S07,712,
Eiled June 24, 1983, and entitled "Method of Making Replaceable
Lamp Unit For Automotive Headlight," there is described a
method of making a replaceable lamp unit wherein conductive
members are mechanically connected to respective lug members by
20 drawing these conductive members through apertures within the
unit's plastic holder. Support wires, which are joined to the
lamp's lead-in wires, are also used and are fixedly positioned
within the conductive members after the aforementioned
mechanical connection.
All of the above-identified Applications are assigned to
the same assignee as the instant invention.
TECHNICAL FIELD
The invention relates to automobile headlights and more
particularly to those wherein a replaceable lamp unit assembly
is utilized (such as those described above).
~:5~2~7~
D-8~-1-005 - 3 - PAT~NT
BACKGROUND
Automobile ~eadlight~ ~herein a replaceable lamp unit i~
employed are know~. Examples are illustra~ed i~ the
belov-identified patent~:
S 2,423,6S4 ~. RYDER
2,750,491 ~.J. ANDERSON
3,593,017 P. CIBIE
3,68a,103 H. DAUMULLER
3,917,939 H.J. SCHMIDT ~T AL
3,987,3Z6 G. LINDAE
4,342,142 Y. N~IDA ET AL
4,344,119 T. B~RGOT
4,412,273 P. HELBIG ET AL
As ~tated, the instant invention i6 related to lamp units
15 oP the variety described above. In particular, the invention
defines a replaceable la~p unit which provides both a hermetic
seal for the unit within the headlight's reflector and, egually
important, as~ures that the electric lamp utilized therewith
will be maintained in strict alignment a~ is neces6ary in
automotive headlights. By the term "hermetic seal" i6 ~eant a
seal vhich prevents the pa6sage of moisture, dust and other
element~ which can adversely afEect the operation of the
headlight. ~y way of example, exce6~ive moisture entering the
headlight can adversely aPfect the reflective coating typically
utilized on the concave reflector of the ~eadlight, and thus
significantly reduce light output therefrom.
In add;tion to providing a hermetic seal, the replaceable
lamp unit defined herein assure~ that alignment of the electric
lamp employed therewith will be maintained. That is, alignment
~25~i~7~
D-85-l-005 - 4 - PA~ENT
of ~e glas~ envelope o~ t~ mp rela~iYe ~o the unit' 6 holder
is provided ~uch t~at ~he fila~nt ~ruc~ure withi~ t~e
envelope (typically either a 6i~gular coiled filame~ or ~wo,
spaced coiled filament~) ~ill be accurately aligned relative ~o
the optic~l axi6 of t~e ~eadlight's refl~ctor when the lamp
unit i~ oriented within the reflector'~ rear opening. Such
align~ene is deemed critical to as6ure optimum headlight output
i~ the direction(~ de6ired.
As also described herein, a preferred light 60urce which
cons~itu~e~ an important part of the replaceable lamp unit
defined herein i6 an electric lamp of t~e tungsten halogen
variety. One example is ~hown in U.S. Patent 3,829,719
l~estlund, Jr. et al), this patent a~signed to the same
as~ignee as the instant invention. In tung~ten halogen lamps,
the tung~ten which con~titutes the filament material is
normally evaporated from the filament during lamp operation and
combines with the halogen to form a gaseous halide~ the halide
preventing the tungs~en from depositing on the internal wall of
the lamp's gla6s envelope. Upon returning to the filament
structure, the halide decomposes, resulting in the deposition
of tungsten back onto the filament structure and the relea~e of
additional halogen gas to as6ure continuation of the cycle.
The halogen cycle is well known in the art and lamps employing
it have been used for some time. Several varieties are
presently manufactured and sold by the assignee of this
invention. In the ca~e of the two beam (dual filament) lamp, a
typical tungsten halogen lamp provides about 65 watts when
operated at high beam and about 45 watts at low beam. As
~tated, it i6 critical that the fllame~t structure of the lamp
within an automobile headlight be preci~ely aligned relative to
the reflector to provide optimum output of the finished
~ 2;55Z7~
D-B5-1-005 5 - PATENT
~eadli~t. A6 will be descrlbed below, such align~en~
con~titute~ an i~psrtant f2a~ure of the replaceable lamp unit
defined herein.
DISCLOSUR~ OF THE INV~NTION
I~ is an ob3ec~ of the instant invention ~ enhan~e the
automobile headlight art and, more particularly, to ~nhance
that portion of the art wherein replaceable unit~ that employ
electric lamps are utilized.
It i~ another object of the invention to provide a
replaceable lamp unit for use within an automobile headlight
which provides a hermetic seal within the hsadlight's reflector
and also maintains the lamp in a Pixed, preci6ioned
relationship relative to the holder thereof such that the lamp
i~ precisely oriented relative to the headlight's reflector
when the unit i~ located therein.
It is an even further object of this invention to provide
an automobile headlight wherein a replaceable lamp unit i8
utilized and wherein such a unit i~ hermetically sealed within
a rear opening of the headlight'6 reflector in such a manner
that the unit's electric lamp is preci~ely oriented relative to
the headlight ' 8 reflector.
It i6 yet another object of the invention to provide such a
replaceable lamp unit and automobile headlight which can be
inexpensively produced in a manner readily adapted to mas6
production.
In accordance with one aspect of the invention, there i6
defined a lamp unit for being removably positioned wîthin a
rear opening of a headlight reflector, the unit comprising an
electrically insulati~e holder for being positioned within the
0~
~25~
D-85-1-005 - 6 - PAT~NT
opening, the holder defining a ~av~ty therein hav~ng at lea6t
one curved 6urface, ~n electric lamp adap~ed for bei~g
~ecuredly retained in a predetermined orie~tation relative to
the ~older, the lamp including an envelope having a filament
~truc~ure therein adapted for being positioned within the
re~lec~or when ~he holder is po~itioned ~i~hin ~he openi~g of
the reflector and at lea~t two lead-in wire~ projecting from
the envelope, and a clamp member including an electrically
in6ulative base po~itioned within the cavity of the holder and
fixedly ~ecured thereto and a pair of electrically conductive
clips ~pacedly po6itioned wit~in the base and ~ecured about the
envelope of the lamp. Each of the lead-in wires is connected
to a respective one of the clip~ at a preci~e location relative
to the filament ~tructure. The base include6 at least one
external ~urface of a curvature sub~tantially similar to the
curved surface of the cavity for engaging the curved surface
whereby the ba~e can be rotatably oriented within the cavity of
the ~older prior to fixed secure~ent thereto.
In accordance with another aspect of the invention, there
i~ defined an automobile headlight compri~ing a reflector
having an opening within a rear portion thereof, a front lens
secured to or forming part of the reflector for directing light
in 3 predetermined manner, and a lamp unit for being removably
positioned within the openiny within the rear portion of the
reflector. The lamp unit includes an elec~rically in~ulative
holder for being po~itioned within the opening, the holder
defining a cavity therein having at lea~t one curved surface,
an electric lamp adapted for being securedly retained in a
predetermined orientation relative to the holder, ~he lamp
including an envelope having a filament ~tructure therein
adapted for being po~itioned within the reflector when the
holder i~ po~itioned within the opening of the reflector, and a
~2S~27~
D- 8 5 -l-OO 5 - 7 - PATENT
claMp ~ember including an el~ctri~ally insulative ba~e
positaonQd within the cavity of the holder and fixedly secured
thereto and a pa~r of electracally conductive clip8 spacedly
posi~ioned within the base and 6ecured about ~he envelope of
the lamp. Eac~ of the lead-in wires i8 connected ~o a
respectiYe one of the clip~ at a preci~e location relative to
~he filament structure. The base includes at lea~t one
ex~ernal ~urface of a curvature substantially ~imilar ~o t~e
curved 6urface of the cavity for engaging the curved 6urface
whereby ~e base can be ro~atably oriented within the cavity of
the ~older prior to fixed securement thereto.
BRI~F DESCRIPTION OF THE DRA~INGS
FIG. 1 is an exploded per~pective view of the electr~c
lamp. insulative holder, and clamp member of the invention in
accordance with a preferred embodiment thereof, and
~ IG. 2 is a side elevational view, in section of the lamp
unit of the invention and further illustrating the re~lector
and lens members of a preferred embodiment of an automobile
headlight of the invention.
BEST MODE FOR CARRYING OUT THE INVENTION
~ or a better understanding of the present invention,
together with other and further objects, advantages and
capabilities thereof, reference is made to the following
disclosure and appended claims in connection with the
above-described drawings.
~ 7~
D-~5-1-005 - ~ - PATENT
~ it~ particul~r atten~ion to the drawing~, the~e ifi
illu6trat~d a lamp unit 10 in ac¢ordance with a pref~rred
embodiment of t~e invention. In FIG. 2, 1 amp unit 10 i8 ~h~wn
in position within an automobile ~eadliqh~ 11 which include~ a
reflector 13 and a front len6 ~ember 1~ which ~æ ~ecured ~o ~he
front o or forming part of ~he reflector. Both re~lector and
len~ components may be of pla~tic or gla86 material or,
alternativelyO a combination thereof.
Lamp unit 10 i& de6igned for being removably po~itioned
wit~in an opening 15 located within the rear, apex portion 16
of reflec~or 13. Apex portion 16 i~ al60 shown afi including a
thickened bo~s portion which project6 externally from the rear
gurface~ of the curvilinear (e.g., paraboloidal~ reflec~or.
~hen in po~ition, lamp unit 10 i~ designed for being
electrically connected to an external connector 17 which
con~titute~ part of the electrical system of the automobile
utilizing headlight 11. More particularly, external connector
17 i~ designed for being in~erted within the rear portion 18 of
the insulative holder 19 which form6 part of unit 10. Such a
connector ~ypically includes a plurality of electrical wire~
which al60 form part of the automobile's electrical circuit.
Connector 17 i8 thus either directly or indirectly connected to
the power ~ource (e.g., 6- or 12-volt battery) typically found
in ~06t of today~s automobiles or other motor vehicles.
Lamp unit 10 include~ the aforementioned electrically
insulative holder 19, an electric lamp 20, and a clamp member
21 which i6 designed for retaining lamp 20 therein and for
being 6ecuredly po6itioned within holder 19. When 80
assembled, lamp unit 10 is then capable of being po~itioned
within rear opening 15 of reflector 13 ~uch that the lamp
extend6 within and i~ ~ub6tantially surrounded by the internal
reflecti~e ~urface6 22 of the reflector.
~25~
D-85 1-005 - 9 - PAT~NT
Tbe pref~rred elec~ric la~p for use in the in6t~nt
invention i~ of the tung~ten halogen ~ariety and includa6 a
gla6s envelope 23 ~av~g located t~erein a ~oiled tungste~
filament 24. Lamp 20 is oriented within reflector 13 ~uch that
ila~ent 2~ i~ 6ub&~ntially centered at the focal point (FP i~
FIG. 2) of the reflector. It i6 ~180 preferred that the
longi~udinal filame~t body lie along the optical axi~ O~-OA of
the ref lector in t~e manner depicted in FIG. 2.
Filament 24 is preferably of coiled coil construc~ion and
includes ~he illustra~ed parallel ~upport rod 24A lying
along~ide the filament'~ main body po~tion. It is also within
the scope of the invention to utilize ~ther type6 of filament
configurations, including those which lie orthogonal to the
reflector's optical aYis. A6 also shown in the drawi~g~, lamp
15 20 include~ only a singular filament 24 within envelope 23. It
i~ also within the s~ope of the invention to utilize a double
filament ~tructure wherein two ~paced apart coiled filaments
are utilized. In the singular filament construction shown
herein, lamp 20 further include6 a pair of electrically
conductive lead-in wires 26 and 27 which project externally
from the envelope ' 6 press-sealed, flattened end portion 28. In
the event that a dual filament structure i~ utilized, a total
of four lead-in wire~ would project externally from sealed end
28. It is thus under~tood with regard to the in6tant
invention, that holder 19 i6 adapted for accommodating both
single and double coiled filament lamps of the type de~cribed
herein.
Clamp member 21 includes an electrically insulative (e.g.,
plastic) base 31 which includes therein a pair of electrically
30 conductive clips 33 and 35. Clips 33 and 35 are 6pacedly
positioned within base 31 and are firmly secured within the
base during molding thereof. Each clip include~ an upper
D-85-1-005 - 10 - PA~ENT
claDping ~ection 37 ~hic~ ~8 de6igned for being ~ecursd about a
re~pective 6ide of tbe Plattened end portion 28 of enYelope
Z3. A~ 6hown in ~IG. 1, each clip i6 of a ~ub~tantially
U-~aped configuration w~en viewed from the top and include~ a
pair of opposed e~pandable 6ide~ for gra~ping the re~pective
~ide on opposite 6ides t~ereof. To facilitate thi~ ~ecurement,
the~e graspiny ~ides can include curvilinear end psrtion6 (a~
~hown~ design~d for fitting within corre6ponding grooYe~ or
610ts 41 formed within end 28.
0 Clip6 33 and 35 are secured about end 28 such tha~ each of
~he projecting lead-in wire~ 26 and 27 respectively pa~
throu~h corresponding opening6 43 located within each clip. A~
best shown in FIG. ~, each lead-in wire penetrates a respective
openi~g to a predetermined depth whereupon it i~ 6ecured (e.g.,
welded) to the clip at this location. It is thus pos~ible
using the teachings of t~e instant in~ention to preci~ely
orient lamp 20 at a predetecmined location relative to the
stationary clips which form part of clamp member 21. This is
deemed an important feature of the invention with regard to
proper alignment of lamp 20 within reflector 13, as will be
further under~tood from ~he ~ollowin~ description. A~ stated,
alignment of the invention's lamp within the illustrated
reflector i.8 deemed critical such that optimum light output
from headlight 11 can be attained. The aforementioned
securement and connection of lead~in wire~ 26 and 27 relative
to cIips 33 and 35 to thus as~ure a precisioned depth of lamp
20 (and particularly the centrally di~posed filament structure
24) constitutes but one of the direction~ in which lamp 20 is
aligned.
With lamp 20 in po~ition and fixedly ~ecured to clamp 21,
the insulative ba~e 31 is then located within a cavity 51
defined within holder 19 and including at least one curved
~s~
D-85-1-005 - 11 - PATENT
~urface 53. A~ best 6~0wn in ~IG. 1, t~ls curved surtace
extend~ 6ub~antially about the entire upper portion of cavity
51 and open~ in a direction toward lamp 20. For purpose6 of
the inven~ion, it i~ preferred that curved 6urface 53 be of
semi-~pherical coniguration, although it is under~tood that
other configurations are within the seope of the invention.
Accordingly, ba~e 31 includes an e~ternal æurface 55 of ~imilar
configura~ion to th~t of ~urface 53. ~hen fully in~erted
within cavity 51, ba~e 31 and holder 19 thus form a ball-joint
type of connection. This unique positioning relationship
enables preliminary pivotal movement ~i.e., in directions P
and P2 in FIG. 2) to define yet another means of aligning
filament structure 24. With the base fully in6erted, ~uch
movement, including that toward and away from the viewer in
PIG. 2, can be accomplished (e.g., by sui$able mechanical
means) in order to attain preci6ion orientation of the filament
struc~ure relative to ~urface 53 within holder 19. Becau~e
this curved surface corresponds to (is located at a fixed
distance from) another surface (i.e., 61) which mate~ again~ a
corresponding external surface of reflector 13, it is thus
possible ~o assure a precise location o~ the lamp~s filament
relative to re~lective 6urfaces 22. It is also understood, of
course, ~hat all of the aforedefined positioning of lamp 20
relative to holder 19 is preferably accomplish2d ex~ernally of
reflector 13.
A6 shown in the drawing6, holder 19 further include~
therein a pair of spaced electrical contacts 71 and 73 molded
therein and each having a flattened blade portion extending
within cavity 51. A~ also shown in FIG. 1, each contact ha~ an
opposing end portion which extends within the oppo6ing end 18
of holder 19 and is de~igned for making contact with respective
contacts within connector 17. To even fur~her facilitate
D- a 5 - l - o o 5 - 12 - P~TE~NT
positioning oP ba~ 31 within cavity 51, a pair of ~paced
aperture6 75 are provided within t~e ba~e. Accordingly, each
flattened blade portion of contacts 71 and 73 i8 de~igned for
being in~erted wit~in and passing through a re~pective one oP
the similarly configured aperture~ (only one ~how~ in FIG. 1).
~hen fully in~erted, each contact is design~d for bei~g ~ecured
(e.g.~ welded) to a re~pective tab Bl which projects from and
for~s part of a respective one oP the invention~ electrically
conducti~e clip~. Prior to 6uch securement, however, ~he
lQ aforementioned rotational or pivotal ~ovement of the lamp is
accomplished. It is understood that ba~e 31 is fir~ly sea~ed
within the 6imilarly shaped cavity 51 at this time. To
facilitate 6uch pivotal motion, each contact i8 tapered from
the wider, flattened blade portion of sub6tantially rectangular
configuration as shown to a much narrower portion at the
approximate point of exit by the conta~t from the main body
por~ion of holder 19. Thi~ tapered configuration is best
illustrated in ~IG. ?. To even ~urther facilitate the
aforedescribed pivotal movement of lamp 20, each of the
described apertures 75 within base 31 is al~o of substantially
tapered configuration. As shown in FIG. 2, each aperture i6
tapered ~uch that the end po~es~ing the larger opening is
located at the location of initial entry by the invention's
electrical contact6 71 and 73. It is thus understood from the
foregoing description that the lamp Z0 can be moved not only in
the described pivotal manner ti.e., Pl and P2) but also in
a rotational manner (i.e., R in FIG. 2).
After all of the foregoing orientations are achieved, base
31 is secured to holder 19 using RF induction heating. That
i~, base 31 is heated to the point that 60ftening of the inner
wall~ of the holder occur~ with the material thereof thereafter
permanently adhering to the ba~e.
~ s~
D-85-1-005 - 13 - PATENT
One i~portant feature oP the invention ~ B that not only has
extremely accurate alignment been achieved in a hiyhly
expeditiou~ manner, but 6uch alignment is achieved wit~out the
need for eeme~t or t~e like as has ~ften been r~quired in lamp
tec~nology of thi~ kind. Curing time for such ~aterial would
add appreciably to the overall assembly cost of 6uch a uni~O
In addition, cemen~6 of thi6 variety typically outgas at
elevat*d ~emperatures, such gas po~sibly adver~ely affecti~g
the finished product (e.g., by affecting the internal
reflective surfaces of the headlight's reflector). The lamp
unit of ~he in~tant invention overcomes both of these
deleteriou~ effect6.
Securemen~ of holder 19 within rear opening 15 is
preferably accomplis~ed in one of two ways. It i~ within the
~cope of the invention to provide internal screw threads or the
like (not shown) within the internal walls of opening 15 and
corresponding male threads on the external surface of holder 19
whereupon the holder can simply be screwed within opening 15.
In a second and more pref erred arrangement, it i~ pos~ible to
utilized a removable cap member (not 6hown) which i6 adapted
for heing positioned on an external surface of tbe neck portion
of reflector 13 (e.g., by providing external grooves or 610t~
therein) with ~he cap member being retained thereon in a
locking arrangement. Portions of the cap would in turn engage
the external flange portions (i.e., U2 in FIG. 2) to retain the
holder against the reflector's neck portion as depicted in FIG.
2. Other means of retention are also po~sible and thus within
the ~cope of the instan~ invention as defined herein. Further
definitlon is thus not believed necessary.
To further assure a sound hermetic seal between the
ex~erior surfaces of holder 19 and tbe internal surfaces of
reflector 13, a ~ilicone O-ring ~3 (FIG. 2) is provided. o-ring
D-85~1-00~ PAT~NT
~3 i~ located wiehin a corre6ponding groove or ~lot within the
~older's external surface and pro~ect~ filigh~ly thereabove to
provide a compression fit between the 0-ring and reflector.
Thus ~here ba~ been 6hown and described a replaceable lamp
uni~ ~or use wiehin an automobile headlight wherein t~e unit
provide6 a hermstic seal between the electric lampl~ holder and
reflector, in addition to an effectiYe means of precisely
aligni~g the lamp in fixed relation~Aip to the holder 6uch that
it in turn will be precisely aligned within the headlight's
reflector. A6 shown in FIG. 2, the au~omobile headlight 11
capable of u6ing lamp unit 10 includes not only the defined
concave reflector 13 but also a corresponding front lens member
14 ~hich. as is known in the art, directs light therethrough in
a predetermined manner. The preferred material Por reflector
15 13, len~ 14, holder 19 and base 31 is a polycarbonate pla6tic.
The electrical contacts 71 and 73 and the conductive retaining
clips 33 and 35 are of a 60und electrically conductive and
weldable material. In one example, tin-plated brass was
successfully utilized.
~hile there have been sho~n and described what are at
present considered the preferred embodiment6 of the invention,
it will be obvious to those skilled in th art that various
changes and modifications may be made therein without departing
from the scope of the invention as defined by and appended
claims.
